Polaris Trail Blazer User manual

A card containing important ATV safety information should be attached
to the owner’s manual on the next page. If you cannot locate this card,
or if it has been removed, please call 1-800-342-3764 for assistance.
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
WARNING

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Copyright 2004 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2005 Trail Blazer Owner’s Manual P/N 9919472

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WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
Polaris Recreational and Utility Vehicles
SSnowmobiles
SAll-terrain vehicles (ATVs)
SWatercraft
SVictory motorcycles
SRANGER utility vehicles
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
manual contains instructions for minor maintenance, but information
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our Parts, Apparel and Accessories (PAA)
products, available through our online store at www.purepolaris.com.
Have your accessories and clothing delivered right to your door!
POLARIS and POLARIS THE WAY OUT are registered trademarks of
Polaris Industries Inc.
LOCTITE is a registered trademark of LOCTITE Corporation.

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TABLE OF CONTENTS
WELCOME 3.................................
VEHICLE IDENTIFICATION NUMBERS 7........
SAFETY 8...................................
FEATURES AND CONTROLS 32...............
OPERATION 44..............................
EMISSION CONTROL SYSTEMS 63............
MAINTENANCE AND LUBRICATION 64.........
SPECIFICATIONS 103........................
POLARIS PRODUCTS 106.....................
TROUBLESHOOTING 107.....................
WARRANTY 111..............................
INDEX 114...................................

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VEHICLE IDENTIFICATION NUMBERS
Record your ATV’s identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place.
Your key can be duplicated only by mating a Polaris key blank with
one of your existing keys, so if both keys are lost, the ignition switch
must be replaced.
Vehicle Model Number:
Frame VIN (1):
Engine Serial Number:
(right front side of engine crankcase)
Key Number (2):
1
31XX
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SAFETY
Operator Safety
WARNING
Failure to follow the warnings contained in this manual can result
in serious injury or death.
A Polaris ATV is not a toy and can be hazardous to operate. This
vehicle handles differently than other vehicles, such as
motorcycles and cars. A collision or rollover can occur quickly,
even during routine maneuvers like turning, or driving on hills or
over obstacles, if you fail to take proper precautions.
Read and understand your owner’s manual and all warnings
before operating a Polaris ATV.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment.
Read and understand your owner’s manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.
Safety Training
When you purchased your new ATV, your dealer offered a hands-on
safety training course that covers all aspects of vehicle safety. You were
also provided with printed materials that explain safe operating
procedures. You should review this information on a regular basis.
If you purchased a used Polaris ATV from a party other than a Polaris
dealer, you can request this free safety training from any authorized
Polaris dealer.
A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws
and regulations concerning the operation of this vehicle in your area.
We strongly advise you to strictly follow the recommended
maintenance program outlined in your owner’s manual. This
preventive maintenance program is designed to ensure that all critical
components on your vehicle are thoroughly inspected at specific
intervals.

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SAFETY
Operator Safety
The following signal words and symbols appear throughout this
manual and on your ATV. Your safety is involved when these words
and symbols are used. Become familiar with their meanings before
reading the manual.
The safety alert symbol, on your vehicle or in this manual, alerts
you to the potential for personal injury.
WARNING
The safety alert warning indicates a potential hazard that may
result in serious injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may
result in minor personal injury or damage to the vehicle.
CAUTION
Acaution indicates a situation that may result in damage to the
vehicle.
NOTE:
Anote will alert you to important information or instructions.

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SAFETY
Operator Safety
WARNING
Serious injury or death can result if you do not follow these
instructions and procedures, which are outlined in further detail
within your owner’s manual.
SRead this manual and all labels carefully, and follow the operating
procedures described.
SNever operate an ATV without proper instruction. Take a training
course.Beginners should receive training from a certified instructor.
Contact an authorized Polaris ATV dealer or call Polaris at
1-800-342-3764 to find out about the training courses nearest you.
SNever allow anyone under 16 years of age to operate this ATV.
SNever permit a guest to operate the ATV unless the guest has read
this manual and all product labels and has completed a certified safe-
ty training course.
SAlways avoid operating an ATV on paved surfaces, including side-
walks, driveways, parking lots, and streets.
SNever operate an ATV on a public street, road or highway, including
a dirt or gravel road.
SNever operate an ATV without wearing an approved helmet that fits
properly. Always wear eye protection (goggles or face shield),
gloves, boots, a long-sleeved shirt or jacket, and long pants.
SNever consume alcohol or drugs before or while operating an ATV.
SNever operate at excessive speeds. Travel at speeds appropriate for
the terrain, visibility and operating conditions, and your experience.
SNever attempt wheelies, jumps or other stunts.
SAlways inspect your ATV before each use to make sure it’s in safe
operating condition. Always follow the inspection and maintenance
procedures and schedules outlined in your owner’s manual.
SAlways keep both hands on the handlebars and both feet on the foot-
rests of the ATV during operation.
SAlways travel slowly and use extra caution when operating on unfa-
miliar terrain. Be alert to changing terrain conditions.
SNever operate on excessively rough, slippery, or loose terrain.
SAlways follow proper turning procedures as described in this manu-
al. Practice turning at low speeds before attempting to turn at faster
speeds. Do not turn at excessive speeds.

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SAFETY
Operator Safety
SAlways have the ATV inspected by an authorized Polaris dealer if
it’s been involved in an accident.
SNever operate on hills too steep for the ATV or for your abilities.
Practice on smaller hills before attempting larger hills.
SAlways follow proper procedures for climbing hills. Check the ter-
rain carefully before ascend a hill. Never climb hills with excessive-
ly slippery or loose surfaces. Shift your weight forward. Never open
the throttle suddenly or make sudden gear changes. Never go over
the top of a hill at high speed.
SAlways follow proper procedures for going downhill and for braking
on hills. Check the terrain carefully before you start down a hill.
Shift your weight backward. Never go down a hill at high speed.
Avoid going down a hill at an angle, which would cause the vehicle
to lean sharply to one side. Travel straight down the hill when pos-
sible.
SAlways follow proper procedures for crossing the side of a hill.
Avoid hills with excessively slippery or loose surfaces. Shift your
weight to the uphill side of the ATV. Never attempt to turn the ATV
around on any hill until you’ve mastered (on level ground) the turn-
ing technique outlined in this manual. Avoid crossing the side of a
steep hill when possible.
SAlways use proper procedures if you stall or roll backwards while
climbing a hill. To avoid stalling, maintain a steady speed when
climbing a hill. If you stall or roll backwards, follow the special pro-
cedure for braking described in this manual. Always dismount on the
uphill side, or to either side if the ATV is pointed straight uphill.
Turn the ATV around and remount following the procedure de-
scribed in this manual.
SAlways check for obstacles before operating in a new area. Never
attempt to operate over large obstacles, such as rocks or fallen trees.
Always follow proper procedures when operating over obstacles as
described in this manual.
SAlways be careful of skidding or sliding. On slippery surfaces like
ice, travel slowly and use extra caution to reduce the chance of skid-
ding or sliding out of control.
SAvoid operating the ATV through deep or fast-flowing water. If it’s
unavoidable, travel slowly, balance your weight carefully, avoid sud-
den movements, and maintain a slow and steady forward motion. Do
not make sudden turns or stops, and do not make sudden throttle
changes.

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SAFETY
Operator Safety
SWet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them lightly several times to allow
friction to dry out the pads.
SAlways check for obstacles or people behind the ATV before operat-
ing in reverse. When it’s safe to proceed in reverse, move slowly and
avoid turning at sharp angles.
SAlways use the size and type of tires specified for your ATV, and
always maintain proper tire pressure.
SNever modify an ATV through improper installation or use of acces-
sories.
SNever exceed the stated load capacity for your ATV. Cargo must be
properly distributed and securely attached. Reduce speed and follow
the instructions in this manual for carrying cargo or towing. Allow a
greater distance for braking.
SAlways remove the ignition key when the vehicle is not in use to
prevent unauthorized use or accidental starting.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-
sumer Product Safety Commission at 1-800-638-2772, or call
Polaris at 1-800-342-3764.
Equipment Modifications
We are concerned for the safety of our customers and for the general
public. Therefore, we strongly recommend that consumers do not
install on a Polaris ATV any equipment that may increase the speed or
power of the vehicle, or make any other modifications to the vehicle
for these purposes. Any modifications to the original equipment of the
vehicle create a substantial safety hazard and increase the risk of bodily
injury.
The warranty on your Polaris ATV is terminated if any equipment has
been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.
NOTE: The addition of certain accessories, including (but not limited
to) mowers, blades, tires, sprayers, or large racks, may
change the handling characteristics of the vehicle. Use only
Polaris-approved accessories, and familiarize yourself with
their function and effect on the vehicle.

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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the operator does
not know how to operate the ATV properly in different situations
and on different types of terrain.
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators should complete the
certified training course offered by Polaris. Operators should
regularly practice the skills learned in the course and the
operating techniques described in the owner’s manual.
For more information about the training course, contact an
authorized ATV dealer or call Polaris at 1-800-342-3764.
WARNING
POTENTIAL HAZARD
Failure to follow the age recommendations for this ATV.
WHAT CAN HAPPEN
Severe injury and/or death could occur if a child under the
minimum age recommendation operates an ATV.
Even though a child may be within the recommended age group
for operating some ATVs, he/she may not have the skills,
abilities, or judgment needed to operate an ATV safely and could
be susceptible to accident or injury.
HOW TO AVOID THE HAZARD
No one under the age of 16 should operate a Polaris ATV.

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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Carrying a passenger on an
ATV.
WHAT CAN HAPPEN
Carrying a passenger
greatly reduces the
operator’s ability to balance
and control the ATV, which
could cause an accident
and injury to the
operator and/or passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. The purpose of the long seat is to
allow the operator to shift position as needed during operation. It
is not intended for carrying passengers.
WARNING
POTENTIAL HAZARD
Operating an ATV
on paved
surfaces, including
sidewalks, paths,
parking lots, and
driveways.
WHAT CAN HAPPEN
ATV tires are designed for
off-road use. Operating on
paved surfaces may
seriously affect the handling and
control of the ATV and could result in loss of control, accident,
and/or injury.
HOW TO AVOID THE HAZARD
Avoid operating the ATV on pavement. If it’s unavoidable, travel
slowly and avoid sudden turns or stops.

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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV on
public streets, roads or
highways.
WHAT CAN HAPPEN
The ATV could collide
with another vehicle.
HOW TO AVOID THE HAZARD
Never operate the ATV on any
public street, road or highway,
including dirt and gravel roads. In many states
it’s illegal to operate ATVs on public streets, roads and highways.
WARNING
POTENTIAL HAZARD
Operating this ATV without
wearing an approved
helmet, eye protection and
protective clothing.
WHAT CAN HAPPEN
Operating an ATV without
an approved helmet
increases the risk of a
severe head injury or
death in the event of an
accident.
Operating without eye protection could result in an accident and
could increase the chance of a severe injury in the event of an
accident.
HOW TO AVOID THE HAZARD
Always wear an approved helmet that fits properly.
Always wear eye protection (goggles or face shield), gloves,
boots, long-sleeved shirt or jacket, and long pants.

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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating the ATV after consuming
alcohol or drugs.
WHAT CAN HAPPEN
Consumption of alcohol and/or drugs
could seriously affect operator
judgment. Reaction time may be slower
and operator balance and perception
could be affected.
Consuming alcohol and/or drugs before
or while operating an ATV could result in
an accident causing severe injury or death.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before or while operating an
ATV.
WARNING
POTENTIAL HAZARD
Operating the ATV at excessive speeds.
WHAT CAN HAPPEN
Excessive speed increases the operator’s chance of losing
control of the ATV, which can result in an accident.
HOW TO AVOID THE HAZARD
Always operate the ATV at a speed that’s proper for the terrain,
visibility and operating conditions, and your experience.

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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps
and other stunts.
WHAT CAN HAPPEN
Attempting stunts increases
the chance of an accident,
including an overturn.
HOW TO AVOID THE
HAZARD
Never attempt wheelies,
jumps, or other stunts. Avoid
exhibition driving.
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Poor maintenance increases the possibility of an accident or
equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your ATV before each use to make sure it’s in
safe operating condition.
Always follow the inspection and maintenance procedures and
schedules described in the owner’s manual.